US6225724B1 - Motor and motor rotor having embedded permanent magnets - Google Patents

Motor and motor rotor having embedded permanent magnets Download PDF

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Publication number
US6225724B1
US6225724B1 US09/357,950 US35795099A US6225724B1 US 6225724 B1 US6225724 B1 US 6225724B1 US 35795099 A US35795099 A US 35795099A US 6225724 B1 US6225724 B1 US 6225724B1
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US
United States
Prior art keywords
slits
sheets
rotor
magnets
laminated
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
US09/357,950
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English (en)
Inventor
Yukari Toide
Akihiro Daikoku
Yuji Nakahara
Toyomi Ohshige
Yoshikazu Ugai
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Mitsubishi Electric Corp
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Mitsubishi Electric Corp
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Filing date
Publication date
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Assigned to MITSUBISHI DENKI KABUSHIKI KAISHA reassignment MITSUBISHI DENKI KABUSHIKI KAISHA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DAIKOKU, AKIHIRO, NAKAHARA, YUJI, OHSHIGE, TOYOMI, TOIDE, YUKARI, UGAI, YOSHIKAZU
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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/03—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—Inner rotors
    • H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
    • H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—Inner rotors
    • H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
    • H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
    • H02K1/2766—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM] having a flux concentration effect
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2201/00—Specific aspects not provided for in the other groups of this subclass relating to the magnetic circuits
    • H02K2201/06—Magnetic cores, or permanent magnets characterised by their skew

Definitions

  • the present invention relates to a motor having a rotor embedded with permanent magnets and a method of manufacturing the motor.
  • the motor When permanent magnets of a sintered type are embedded in a motor, the motor is manufactured by inserting permanent magnets into slits formed in a rotor core and filling the gaps caused by errors in their form by a filler and/or a bonding agent and then fixing the permanent magnets to the rotor core by mechanically joining the permanent magnets to the rotor core using joining methods like bolts and nuts, methods have obstructive factors in forming the permanent magnets which reduce productivity of the motor assembly. Further, in the case where the permanent magnets are formed by injecting a powdered material constituting permanent magnets, it is necessary to introduce a rotor under a high temperature of 500° C. or more for a long period, which requires expensive equipment and reduces reliability due to residual stress and deformation caused by the application of heat to the rotor, and so on.
  • FIG. 14 is disclosed in JP-A-10-112946 to solve the above-mentioned problems, wherein a structure of rotor of a brush-less d.c. motor with embedded permanent magnets is shown.
  • permanent magnets formed by bonding magnetic powders having a hard magnetic phase and a resin with a soft magnetic phase are inserted in slots 2 formed at four positions in a rotor core 1 ; and thereafter the permanent magnets are fixed to the rotor core 1 by adhering or mechanically joining using bolts and nuts.
  • a motor embedded with permanent magnets which is integrally formed by directly injecting bond magnets made of a resin having dispersed powders of permanent magnet material into slits, respectively provided in each of various poles of a rotor core, and by curing the bond magnets. This removes the need for using a bonding agent or a filler and fixing of the permanent magnets using mechanically binding means such as bolts and nuts.
  • the motor embedded with permanent magnets wherein the resin forming the bond magnets is a thermoplastic resin.
  • the motor embedded with permanent magnets wherein the resin forming the bond magnets is a thermoset resin.
  • the motor embedded with permanent magnets wherein a rotor is composed of a plurality of rotor blocks piled in its axial direction, the rotor blocks respectively formed by laminating a plurality of rotor core plates.
  • the motor embedded with permanent magnets wherein the rotor blocks have spacers formed thereon being made of thin layers of the bond magnets having shapes of recesses and projections, complementary each other, respectively on surfaces in the axial direction of the rotor blocks; and the rotor blocks are piled so that the recesses and projections of adjoining spacers of the rotor blocks are engaged with each other.
  • a method of manufacturing a motor embedded with permanent magnets comprising steps of: injecting bond magnets, made of a thermoplastic resin including dispersed powders of permanent magnets material having a melt flow rate of 0.3 or more under test conditions of a temperature of 300° C., a load of 20 kg-f, an inner diameter of die of 1.0 mm, and a thickness of die of 1.0 mm in conformity with a definition of JISK7210, into slits respectively provided in each of poles of rotor core by heating and fluidizing the bond magnets, and curing the bond magnets.
  • a method of manufacturing a motor embedded with permanent magnets comprising steps of: injecting bond magnets, made of a thermoset resin including dispersed powders of permanent magnets material having a viscosity of 1,000 through 10,000 cP, into slits respectively provided in each of poles of rotor core, and curing the bond magnets.
  • FIG. 1 is a perspective view showing a rotor core assembly of a motor embedded with magnets according to the present invention
  • FIG. 2 is a graph illustrating a relationship between rheological characteristics of bond magnets made of a thermoplastic matrix polymer and a rate of filling the bond magnets into slits;
  • FIG. 3 is a graph illustrating a relationship between rheological characteristics of bond magnets made of a thermoset matrix polymer and a rate of filling the bond magnets into slits;
  • FIG. 4 is a plan view of a rotor core assembly for showing arrangement of slits according to the present invention
  • FIG. 5 is a plan view of a rotor core assembly for showing a method of injecting bond magnets according to the present invention
  • FIG. 6 is a plan view of a rotor core assembly for showing a variation of arrangement of permanent magnets according to the present invention
  • FIG. 7 is a plan view of a rotor core assembly for showing another variation of arrangement of permanent magnets according to the present invention.
  • FIG. 8 is a plan view of a rotor core assembly for showing another variation of arrangement of permanent magnets according to the present invention.
  • FIG. 9 is a plan view of rotor core assembly for showing another variation of arrangement of permanent magnets according to the present invention.
  • FIG. 10 is a perspective view of a rotor core assembly for showing a structure of skewed core according to the present invention.
  • FIG. 11 is a perspective view of a rotor core assembly for showing another structure of skewed core according to the present invention.
  • FIG. 12 is a perspective view of another rotor core assembly of a motor embedded with magnets according to the present invention.
  • FIGS. 13A and 13B are a perspective views of core blocks for showing overlapped surfaces of the core blocks of a rotor core assembly according to the present invention.
  • FIG. 14 schematically shows a structure of a rotor of a conventional motor embedded with magnets.
  • FIGS. 1 through 14 A detailed explanation will be given of preferred embodiments of the present invention in reference to FIGS. 1 through 14 as follows. For simplicity the same numerical references are used for the same or similar portions and description of similar portions is omitted. Similarly, in descriptions of embodiments, portions overlapping those of precedent embodiments are omitted.
  • FIG. 1 is a perspective view of a rotor core assembly of a motor embedded with magnets having four poles for showing Embodiment 1 of the present invention.
  • numerical reference 1 designates a rotor core made of electromagnetic steel, in which a number of slits 11 and a number of magnetic paths 12 are formed in a direction of a center of the rotor core to have a projected shape.
  • FIG. 1 an example that nine layers of slits 11 and eight layers of magnetic paths 12 are used is shown.
  • Magnets made of a matrix polymer having powdered material of permanent magnets (hereinbelow referred to as bond magnets) 2 dispersed therein are embedded in the slits 11 .
  • the number of layers of permanent magnets provided in each pole influences properties of the bond magnets used for embedding and a distribution of magnetic flux in air gaps. Therefore, it is necessary to appropriately determine the number of the slits 11 and the number of the magnetic paths 12 in response to the properties of the bond magnets to be used and a performance of desirable motor embedded with magnets, wherein FIG. 1 is one of such examples.
  • the diameter of the rotor core 1 is 60 mm and formed by laminating thirty rotor core plates punched out of a silicon steel plate having a thickness of 0.35 mm to be a predetermined shape, each of the rotor core plates being formed with nine slits having a width of 0.5 mm with equal intervals of 0.5 mm for the number of poles, i.e. four groups.
  • the bond magnets 2 are filled with a pressure of 1,000 kg-f/cm 2 at rate of 35 cm 3 /s, after being heated to 170° C.
  • the bond magnets are made of the matrix polymer of nylon 12 and the powdered material of permanent magnet is ferrite powders.
  • Magnets for orientating are disposed in the mold, the magnets for orientating are magnetized simultaneously with formation of the bond magnets.
  • FIG. 2 is a graph for illustrating a relationship between a melt flow rate indicating rheological characteristics of the bond magnets and a filling rate of the bond magnets into an internal space of the slits 11 at a time of manufacturing the rotor core assembly using the bond magnets made of a plurality of thermoplastic matrix polymers having different viscosities as described with reference to FIG. 1 .
  • Characteristics of filling the bond magnets into the slits are evaluated by the melt flow rate (hereinbelow referred to as MFR) in testing conditions of a temperature of 300° C., a load of 20 kg-f, a diameter of die of 1.0 mm, and a thickness of die of 1.0 mm, in conformity with the standards of JISK7210.
  • MFR melt flow rate
  • the filling rate of the bond magnets into the inside of the slits becomes substantially 100%.
  • the filling rate is abruptly dropped.
  • the MFR of the bond magnets filled into the slits is 0.3 cc/sec or more.
  • FIG. 3 is a graph concerning the bond magnets using a plurality of thermoset matrix polymers having different viscosities, corresponding to FIG. 2.
  • a filling rate of bond magnets into the inside of the slits is substantially 100% when the viscosity is 10,000 cP or less. When the viscosity is more than 10,000 cP, the filling rate is abruptly lowered.
  • a lower limit of viscosity should be about 1,000 cP in consideration of stability of distribution of particles of the powdered material of permanent magnet in the matrix polymer and leakages from the mold at a time of filling into the slits. Therefore, it is desirable that the viscosity of bond magnet is in a range of 1,000 cP through 10,000 cP at a temperature of 25° C.
  • the material of permanent magnet may be powders of ferrite or powders of neodymium system or samarium cobalt system.
  • the matrix polymer can be properly selected in response to a heat proof margin of a motor, wherein the above-mentioned nylon, polyphenylenesulfide (PPS), ethylene-ethylacrylate (EEA), or the like is used as the thermoplastic resin, and epoxy, polyimide, or the like is used as the thermoset resin.
  • the bond magnets 2 are embedded by connecting adjoining poles by continuous slits 11 . It is also possible to appropriately separate slits 11 by forming bridges 13 as shown in FIG. 4 . This is to avoid deformation of magnetic paths 12 being barriers between the slits 11 caused by enhancement of mechanical strength of the rotor core assembly and a pressure difference of the bond magnets among the slits at a time of injecting the bond magnets 2 into the slits 11 at a high pressure. Further, it is possible to use an example that the slits are opened into an outer peripheral surface of the rotor core for preventing magnetic leakage paths from emerging at around the outer periphery of the rotor core. FIG. 4 shows only an example of separating the slits, and therefore, the method is not limited to that shown in FIG. 4 .
  • the bond magnets 2 In order to avoid the deformation of the magnetic paths being the barriers between the slits 11 caused at a time of injecting the bond magnets 2 , it is possible to inject the bond magnets under a state that pins 3 are inserted in longitudinal directions of the slits with appropriate intervals as shown in FIG. 5 .
  • the pins 3 are fixed to the mold for forming the bond magnets or to projections or recesses properly disposed in the slits at positions of fixing the pins.
  • the pins 3 may be removed after curing the bond magnets or maintained without removal. In case that the pins 3 are maintained without removing, it is preferable to use a non-magnetic material.
  • the bond magnets 2 are magnetized by the magnets for orientating disposed on the mold at a time of curing after injection. Succeedingly, the bond magnets 2 are once demagnetized after a completion of curing and magnetized later again. Needless to say that the bond magnets 2 are magnetized after curing without magnetizing by the magnets for orienting.
  • a device for magnetizing using pulsating magnetic fields or the like may be used.
  • FIGS. 6 through 9 show variations of arrangement of permanent magnets. However, arrangement patterns of permanent magnet are only examples and a content of invention is not limited to these examples. Because the permanent magnets are firmly in contact with the rotor core at the time of curing, it is not necessary to fix the permanent magnets using fixing by bonding agents and/or fillers or a mechanically binding means such as bolts and nuts.
  • the rotor core plates are formed by punching out the silicon steel plate above, it is not limited thereto.
  • the rotor core plates may have a block-like shape, being integrally formed out of a magnetic material by a method like etching.
  • FIG. 10 is a perspective view of a rotor core assembly of a motor embedded with magnets according to Embodiment 2 of the present invention.
  • numerical reference 14 designates marks indicating intermediate positions of a group of slits, which marks indicate positions common to laminated core plates.
  • a method of realizing skewed core aimed to prevent pulsations of output torque and noises by a high harmonic current from occurring, which pulsations and noises are caused depending on combinations of spaces of coil slots provided in an inner diameter of a stator assembly and spaces between magnetic poles at an outer periphery of the rotor core assembly.
  • the marks 14 in the core plates composing the rotor core assembly are successively shifted in a rotational direction as the core plates are laminated.
  • the rotor core 1 formed by laminating the core plates while successively shifting in the rotational direction has bond magnets 2 embedded in their slits. It is preferable to make a deviation ⁇ between the core plates a half or less of the width of the slits 11 so that the bond magnets are equally injected into the slits.
  • the above-mentioned mark 14 is referred to, for the convenience, in describing the present invention. Therefore, it is not requisite for the core plates. Cutouts having a notch-like shape provided in an outer periphery of the core plates may be used instead of the marks 14 for the purpose of, for example, registering the core plates.
  • Sets of core blocks obtained by dividing the height of rotor core to a predetermined number are laminated. Bond magnets 2 are embedded in slits of each of the sets of core block 1 a in a similar manner to that described in reference of FIG. 1 .
  • the sets of core block 1 a are piled while shifting marks 14 , respectively of the sets of core block 1 a, in their rotational direction to thereby form a rotor core assembly.
  • the bond magnets 2 are embedded after dividing the height of the laminated rotor core, a pressure of injecting the bond magnets 2 into the slits 11 can be low, whereby magnetic paths 12 being barriers between the slits 11 are scarcely deformed.
  • FIG. 12 is a perspective view of a rotor core assembly of a motor embedded with magnets according to Embodiment 3 of the present invention.
  • FIGS. 13A and 13B are perspective views of core blocks 1 a of a rotor core for showing overlapping surfaces of the core blocks 1 a.
  • numerical reference 21 designates interposed pieces formed between the overlapped surfaces of the core blocks 1 a;
  • numerical references 21 a and 21 b designate interposed pieces respectively formed on two surfaces to be overlapped each other, wherein the interposed pieces 21 a and 21 b have the same thicknesses and are in complementary shapes, in which each of recesses is inverted at each of corresponding projections.
  • a positional relationship between the slits and the interposed pieces 21 a or 21 b is set so that the slits 11 are arranged in a straight line in the entire height of the laminated rotor core assembly or the skewed core is established as in a similar manner to that described in reference of FIG. 9 .
  • the thickness of the interposed pieces 21 is necessary to be small enough to keep a ratio of the total thickness of core plates to the laminated height of the rotor core assembly, i.e. an occupying rate of the core plates, without substantial decrement.
  • the first advantage of the present invention is that a rotor embedded with permanent magnets having a shape with extremely high degrees of freedom can be realized, and it is not necessary to fix the permanent magnets by securing using a bonding agent and/or a filler or by a mechanically binding means such as bolts and nuts since the permanent magnets are firmly in contact with the rotor core after curing.
  • the second advantage of the present invention is that bond magnets having extremely variable characteristics can be embedded in a rotor core of a motor embedded with magnets.
  • the third advantage of the present invention is that bond magnets can be embedded by dividing the laminated heights of rotor core; a pressure of injecting the bond magnets into slits can be small; magnetic paths being barriers between slits are scarcely deformed; and preferable skewed core can be realized by successively shifting phases of rotor blocks in their rotational direction when the rotor blocks are piled in their axial direction.
  • the fourth advantage of the present invention is that an operation of removing burrs can be omitted and registration in a rotational direction of core block in an operation of overlapping the core blocks becomes easy, whereby productivity is improved.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)
US09/357,950 1998-10-23 1999-07-21 Motor and motor rotor having embedded permanent magnets Expired - Fee Related US6225724B1 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP30218798 1998-10-23
JP10-302187 1998-10-23
JP11-075612 1999-03-19
JP07561299A JP4089072B2 (ja) 1998-10-23 1999-03-19 永久磁石埋込み形モータ

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US (1) US6225724B1 (de)
JP (1) JP4089072B2 (de)
KR (1) KR100362323B1 (de)
DE (1) DE19941107B4 (de)
FR (1) FR2785105B1 (de)
TW (1) TW434973B (de)

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JP4089072B2 (ja) 2008-05-21
KR100362323B1 (ko) 2002-11-25
JP2000197320A (ja) 2000-07-14
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TW434973B (en) 2001-05-16
KR20000028626A (ko) 2000-05-25

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